Cantilevered mask for openings in additively manufactured part

Abstract

A mask is provided for an additively manufactured part including a plurality of openings in a surface of the part. The mask is made with the part and includes an attachment ligament configured to integrally couple to the part adjacent the plurality of openings. A cover member include a proximal end integrally coupled to the attachment ligament and distal end extending at least partially over the plurality of openings. A detachment member may optionally extend from adjacent the cover member. The attachment ligament is the sole connection to the part. The mask may have an L-shape in cross-section.

What is claimed is: 
     
       1. A mask for an additively manufactured part, the part including a plurality of openings in a surface thereof, the mask comprising:
 an attachment ligament configured to integrally couple to the part adjacent to the plurality of openings in a cantilever fashion; 
 a cover member including a proximal end integrally coupled to the attachment ligament and a distal end extending at least partially over the plurality of openings, the distal end of the cover member separated from the part by a first spacing, 
 wherein the attachment ligament is the only connection from the cover member to the part; and 
 a detachment member extending from the cover member. 
 
     
     
       2. The mask of  claim 1 , wherein the attachment ligament has a minimum width ranging from 0.01 millimeters (mm) to 0.50 mm. 
     
     
       3. The mask of  claim 1 , wherein the plurality of openings are positioned in the surface of the part across a distance, and wherein the cover member extends at least partially over the plurality of openings along an entirety of the distance. 
     
     
       4. The mask of  claim 3 , wherein the attachment ligament integrally couples to the part at spaced connection points along the distance. 
     
     
       5. The mask of  claim 4 , wherein the attachment ligament integrally couples to the part along between 25% and 60% of the distance. 
     
     
       6. The mask of  claim 1 , wherein the first spacing is between 0.88 millimeters (mm) to 1.4 mm (0.035 to 0.055 inches). 
     
     
       7. The mask of  claim 1 , wherein the first spacing has a dimension configured to prevent a coating applied over the cover member from bridging from the cover member to the part and prevent a peening material from passing therethrough. 
     
     
       8. The mask of  claim 1 , wherein the part, the attachment ligament, the cover member and the detachment member include a plurality of integral material layers. 
     
     
       9. The mask of  claim 1 , further comprising at least a pair of pivot restraint members extending from the distal end of the cover member,
 wherein each pivot restraint member has a distal end spaced from the part by a second spacing less than the first spacing in a first, relaxed position of the cover member and in contact with the part in a second position in which a bending moment force is applied to at least one of the attachment ligament, the cover member and the detachment member. 
 
     
     
       10. The mask of  claim 9 , wherein the second spacing is approximately 0.1 millimeters (mm). 
     
     
       11. The mask of  claim 1 , wherein the detachment member includes a tool receiving feature therein configured to receive a tool, and the cover member includes a force receiving surface at a distance from the detachment member,
 wherein a force applied by a tool positioned in the tool receiving feature of the detachment member applies a lever force to detach the attachment ligament from the part. 
 
     
     
       12. The mask of  claim 1 , wherein the cover member includes a pair of squared corners, the squared corners on opposing sides of the attachment ligament. 
     
     
       13. The mask of  claim 1 , wherein the attachment ligament includes a lower portion integrally coupled to the part and having a first width, and an upper portion above the lower portion and having a second width that is wider than the first width. 
     
     
       14. An additively manufactured (AM) structure, comprising:
 a part including a plurality of openings in a surface thereof; 
 a mask including:
 an attachment ligament configured to integrally couple to the part adjacent to the plurality of openings in a cantilever fashion; 
 a cover member including a proximal end integrally coupled to the attachment ligament and a distal end extending at least partially over the plurality of openings, the distal end of the cover member separated from the part by a first spacing; and 
 a detachment member extending from the cover member, 
 
 wherein the attachment ligament is the only connection from the cover member to the part, and 
 wherein the part, the attachment ligament, the cover member and the detachment member include a plurality of integral material layers. 
 
     
     
       15. The AM structure of  claim 14 , wherein the plurality of openings are positioned in the surface of the part across a distance, and wherein the cover member extends at least partially over the plurality of openings along an entirety of the distance, and the attachment ligament integrally couples to the part at spaced connection points along the distance. 
     
     
       16. The AM structure of  claim 14 , wherein the first spacing has a dimension configured to prevent a coating applied over the cover member from bridging from the cover member to the part and prevent a peening material from passing therethrough. 
     
     
       17. The AM structure of  claim 14 , further comprising at least a pair of pivot restraint members extending from the distal end of the cover member,
 wherein each pivot restraint member has a distal end spaced from the part by a second spacing less than the first spacing in a first, relaxed position of the cover member and in contact with the part in a second position in which a bending moment force is applied to at least one of the attachment ligament, the cover member and the detachment member. 
 
     
     
       18. The AM structure of  claim 14 , wherein the detachment member includes a tool receiving feature therein configured to receive a tool, and the cover member includes a force receiving surface at a distance from the detachment member,
 wherein a force applied by a tool positioned in the tool receiving feature of the detachment member applies a lever force to detach the attachment ligament from the part.